System and method for customizing footwear

ABSTRACT

A system and method for manufacturing a footwear component that may be customized based on consumer data and fitted with a footwear sole assembly to form part of footwear. The footwear sole assembly of the footwear can be tailored or customized for a particular consumer. The footwear component may be produced with additive manufacturing techniques, optionally allowing the footwear to be customized at or near a point of sale. In one embodiment, the density of the footwear sole assembly, or portions thereof, may be varied to align with the consumer data.

TECHNICAL FIELD

The present application relates to systems and methods for customizing footwear and more particularly toward generating customizable footwear and a customized footwear component.

BACKGROUND

Conventional footwear is often designed and manufactured long before the footwear makes its way to a point of sale, such as a brick and mortar storefront. Conventional footwear made and sold in this manner is not customizable. For instance, the customization options available to the consumer are limited to adding aftermarket insoles or aftermarket orthotics.

From the consumer's perspective, at the point of sale, the consumer can choose from an available array of footwear in various styles and sizes. Each style of conventional footwear is designed and manufactured to conform to an average consumer's preferences or needs, or both. This way, a consumer who is not necessarily average may find the available selection to be inadequate. One option available to the non-average consumer is to purchase an aftermarket insole or orthotic for placement within the void of the footwear that accepts the consumer's foot. Another option is to look through the various styles of footwear until an acceptable one is found. Both of these options often leave the non-average consumer feeling unsatisfied with the footwear.

From the manufacturer's perspective, at the point of sale, if a consumer likes the look of a particular style but not the feel, there is potential for a lost sale and revenue. The consumer may find footwear from another manufacturer to be more aligned with the consumer's preferences or needs, or both, and so the consumer may purchase that footwear instead. For instance, in the realm of running footwear, different consumers prefer different degrees of cushion, and different manufacturers offer footwear of different degrees of cushion. One consumer may find a manufacturer with offerings that align with their cushion preferences, and will likely remain loyal to that manufacturer. Another consumer may find and remain loyal to another manufacturer for similar reasons. In this way, both manufacturers may risk losing an existing consumer if efforts are made to change the look and feel of the manufacturers' footwear to satisfy the other consumer.

SUMMARY OF THE DESCRIPTION

The present disclosure is directed to a system and method for manufacturing a footwear component that may be customized based on consumer data and fitted with a footwear sole assembly to form part of the footwear. The footwear sole assembly of the footwear can be tailored or customized for a particular consumer. The footwear component may be produced with additive manufacturing techniques, optionally allowing the footwear to be customized at or near a point of sale. In one embodiment, the density of the footwear sole assembly, or portions thereof, may be varied to align with the consumer data.

In one embodiment, a method of generating a custom footwear component is provided. The method may include providing a footwear sole assembly with a sole body having a plurality of voids, with each of the voids being constructed to accept a support member. The method may include obtaining consumer data pertaining to a physical characteristic of the consumer, and generating an encoded description of a plurality of the support members based on the consumer data. The plurality of the support members may be additively manufactured in accordance with the encoded description, and disposed in the voids defined by the sole body.

The consumer data in one embodiment may be based on sensor output from a sensor configured to detect a characteristic of the consumer. The sensor output may be a pressure profile of the consumer's foot.

In one embodiment, a system for generating a footwear component for footwear is provided. The footwear may include a sole body with a plurality of voids, and the system may include a sensor configured to sense a physical characteristic of a consumer to generate consumer data pertaining to the physical characteristic. The physical characteristic may be a pressure profile of the consumer's foot, and the sensor may be a pressure pad on which the consumer may stand. The sensor may be configured to detect dynamic characteristics of the consumer, such as pressure of the consumer's foot during a stride (e.g., walking or running).

The system may include a control system operably coupled to the sensor and configured to receive the consumer data. The control system may be configured to generate an encoded description of a plurality of support members based on the consumer data, where each of the plurality of support members is configured to be disposed within a void of the plurality of voids of the sole body.

In one embodiment, a footwear component for footwear is provided. The footwear may include a sole body with a plurality of voids. The footwear component may include a support member and a plurality of connecting members. The support member may include an upper support surface and a lower support surface opposite the upper support surface. The support member may include an outer side surface extending from the lower support surface to the upper support surface, where the support member is configured to be disposed in a void of the plurality of voids defined by the sole body.

Each of the plurality of connecting members may be configured to connect a plurality of the support members, whereby the plurality of the support members may be disposed into the plurality of voids of the sole body.

In one embodiment, a sole body for footwear is provided with a midsole and an outsole. The midsole may include an upper midsole surface and a lower midsole surface. The upper midsole surface may be positionable adjacent to an upper of the footwear, and may include a forefoot zone, a midfoot zone, and a heel zone. The midsole may include a plurality of voids defined at least in part by the upper midsole surface, where each of the plurality of voids is configured to accept a support member.

The midsole may include one or more channels defined at least in part by the upper midsole surface, where the one or more channels may be disposed between at least two of said plurality of voids.

The outsole may be coupled to the lower midsole surface of the midsole and may include a ground contacting surface.

These and other advantages and features of the invention will be more fully understood and appreciated by reference to the description of the current embodiment and the drawings.

Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention may be implemented in various other embodiments and of being practiced or being carried out in alternative ways not expressly disclosed herein. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a representative view of a footwear component in accordance with one embodiment.

FIG. 2 shows a perspective view of the footwear component of FIG. 1.

FIG. 3 shows a perspective view of a footwear sole assembly in accordance with one embodiment.

FIG. 4 shows a top view of the footwear sole assembly of FIG. 3.

FIG. 5 shows a top view of the footwear sole assembly of FIG. 3 joined with the footwear component of FIG. 1 in accordance with one embodiment.

FIG. 6 shows a plurality of support members in accordance with one or more embodiments.

FIG. 7 shows a neutral form of a support member in accordance with one embodiment.

FIG. 8 shows a front and top view of the neutral form of FIG. 7.

FIG. 9 shows a support member in accordance with one embodiment.

FIG. 10 shows a support member in accordance with one embodiment.

FIG. 11 depicts a support member in accordance with one embodiment.

FIG. 12 shows a support member in accordance with one embodiment.

FIG. 13 shows a system in accordance with one embodiment for manufacture of a footwear component and custom footwear.

FIG. 14 shows a pressure profile of a person obtained in accordance with one embodiment.

FIG. 15 shows custom footwear in accordance with one embodiment.

DESCRIPTION

A system in accordance with one embodiment is configured to manufacture a footwear component, similar to the footwear component shown in FIGS. 1-2 and generally designated 200. The footwear component 200 may be customized based on consumer data and fitted with a footwear sole assembly that can form part of footwear. This way, the sole assembly of the footwear can be tailored or customized for a particular consumer. The footwear component 200 may be produced with additive manufacturing techniques, optionally allowing the footwear to be customized at or near a point of sale. In one embodiment, the density of the footwear sole assembly, or portions thereof, may be varied to align with the consumer data. The sole assembly may be manufactured prior to obtaining the consumer data, potentially reducing the number of steps to generate the custom footwear.

In the illustrated embodiments of FIG. 2, the footwear component 200 includes a plurality of support members 240 and one or more connecting members 220 configured to connect two or more of the support members 240. The support members 240 in the illustrated embodiment are coupled together in the form of a network, with vertices corresponding to positions of the support members 240 and edges corresponding to the one or more connecting members 220. One or more openings 221 may be defined in accordance with this configuration. However, it should be understood that the present disclosure is not limited to this configuration. Example alternative configurations include one or more of the support members 240 being separate from each other or isolated, or a plurality of the support members 240 being coupled to each other in an alternative manner, such as a connector plate that is solid without the openings 221.

The footwear component 200 may include one or more of the following regions: a heel region 214, a midfoot region 212, and a toe region 210. These regions may correspond generally and respectively with the heel area of a consumer's foot, a midfoot area of the consumer's foot that is largely aligned with an arch region, and the forefoot region of the consumer's foot. The footwear component 200 may be constructed for positioning in only one of these regions, or one or more of these regions as noted herein. The construction of the footwear component 200 may vary among the regions, and potentially within a region. For instance, in the illustrated embodiment, the height of the support members 240 in the heel region 214 is larger than the height of the support members 240 in the toe region 210. As another example, in at least a portion of the midfoot region 212 of the illustrated embodiment, the height of the support members 240 tapers from larger nearer to the heel region 214 to smaller nearer to the toe region. In yet another example, the height of the support members 240 near the medial side of the footwear component 200 may be different from the height of the support members 240 near the lateral side of the footwear component 200.

The footwear component 200 may define an upper boundary surface 216 and a lower boundary surface 218. These surfaces in the illustrated embodiment of FIGS. 1-2 are defined by the shape of the footwear component 200. More particularly, the upper boundary surface 216 may be defined at least in part by the upper surfaces of the plurality of support members 240, and the lower boundary surface 218 may be defined at least in part by the lower surfaces of the plurality of support members 240. The footwear component 200 in the illustrated embodiment may be constructed so the lower boundary surface 218 defined by aspects of the footwear component 200 is ground facing in use and the upper boundary surface 216 is foot facing in use.

The footwear component 200 is described herein as being capable of production with an additive manufacturing system—however, it should be understood that the present disclosure is not so limited. The footwear component 200, or a portion thereof, may be manufactured without additive manufacturing, such as injection molding, with one or more materials. As an example, the midsole material may be formed of form (e.g., ethylene-vinyle acetate [EVA] foam), rubber (e.g., blown nitrile rubber), and thermoplastic polyurethane (TPU). All or a portion of the footwear component 200 may be produced by additive manufacturing—e.g., in one embodiment, one or more aspects of the footwear component 200 may be manufactured prior to additive manufacturing production. The footwear component 200, as noted herein, may be manufactured from two or more different materials.

The density of the footwear component 200 may vary in any direction, including along the length, width or height, or a combination thereof. For instance, the material density of the footwear component 200 may decrease functionally from the upper boundary surface 216 to the lower boundary surface 218. The material density function may be linear or exponential in one embodiment.

Turning to the illustrated embodiment of FIG. 3, the footwear component 200 may be configured to interface with a footwear sole assembly 100. The footwear sole assembly 100 may define a plurality of voids 140, each of which may be constructed to accept a support member 240 of the footwear component 200. A depth of the void 140 may be equal to or greater than a height of a support member 240 disposed in the void 140. In one embodiment, the depth of the void 140 may be greater than a height of a support member 240 disposed in the void 140—this may enable staged compression of the footwear sole assembly 100 and the support member 240 at least in part because the footwear sole assembly 100 may compress in a first stage before the support member 240 bottoms out the void 140 resulting in compression in a second stage of both the footwear sole assembly 100 and the support member 240.

In one embodiment, the depth of the void 140 may be less than a height of a support member 240 disposed in the void 140—this configuration may result in compression of the support member 240 within the void 140 so that the entire support member 240 fits within the void 140 and so that the support member 240 does not protrude significantly above a foot facing surface of the footwear sole assembly 100.

The footwear sole assembly 100 in the illustrated embodiment of FIG. 3 may include a heel region 114, a midfoot region 212, and a toe region 210. These regions may correspond generally and respectively with the heel area of a consumer's foot, a midfoot area of the consumer's foot that is largely aligned with an arch region, and the forefoot region of the consumer's foot. The footwear sole assembly 100 may include an upper surface 116 that is foot facing in use and a lower surface 118 that is ground facing in use. Although the footwear sole assembly 100 is shown as a midsole, the present disclosure is not so limited—the footwear sole assembly 100 may include a midsole and an outsole constructed to provide ground traction. The outsole may include a plurality of traction elements constructed to interface with the ground in use.

The footwear sole assembly 100 may be manufactured in a variety of ways, including for example without limitation, injection molding, blow molding, and additive manufacturing, or a combination thereof. The footwear sole assembly 100 may be formed of one or more types of materials, such as rubber, foam, and TPU, or a combination thereof. The footwear sole assembly, as discussed herein, may include a midsole and an outsole, which may be constructed of different materials, or at least one material of the outsole or the midsole being different from at least one material of the other. For instance, the midsole may be formed all or primarily from foam, whereas the outsole may be formed all or primarily from rubber.

The footwear sole assembly 100 may define one or more channels 120 constructed to accept the one or more connecting members 220 of the footwear component 200. As an example, a connecting member 220 may be accepted in a channel 120 so that the upper surface 116 is substantially continuous through the region in which the channel 120 is defined and the connecting member 220 is disposed. In other words, the channel 120 may accept the connecting member 220 such that there is little or no discontinuity between the upper surface 116 adjacent the channel 120 and an upper surface of the connecting member 220.

The cross section of one or more channels 120 may vary from application to application, and optionally within the footwear sole assembly 100 in the case of more than one channel 120 as shown in the illustrated embodiment of FIG. 3. For instance, the cross section of a channel 120 may be substantially circular or curved, trapezoidal, rectangular, or V-shaped, or a combination thereof. The one or more connecting members 220 of the footwear component 200 may be constructed to substantially conform to the cross section of the channel 120.

In an alternative embodiment, the footwear sole assembly 100 may not include one or more channels 120. In such a construction, connections between the support members 240 while maintaining a substantially continuous upper surface 116 of the footwear sole assembly 100 may be achieved in a variety of ways. An example construction includes a recessed area defined by the footwear sole assembly 100 with a perimeter step (possibly with a slope that is vertical or less than vertical). In this configuration, the plurality of support members 240 may be connected by a substantially solid plate with a perimeter edge surface constructed to align with the perimeter step of the footwear sole assembly 100. In another example construction, the plurality of support members 240 may be connected by a substantially solid plate (potentially made of material similar to the support members) with a perimeter edge surface that aligns with a perimeter edge surface of the footwear sole assembly 100, thereby providing an upper surface for the customized sole assembly that is substantially continuous.

In the illustrated embodiment of FIG. 4, a top view of the footwear sole assembly 100 of FIG. 3 is shown without the footwear component 100. The illustrated embodiment of FIG. 5 provides a top view of the footwear sole assembly 100 and the footwear component 200 to form a customized footwear sole assembly 400. The footwear component 100 may be joined with the footwear sole assembly 100 to form the customized footwear sole assembly 400. The joint may be effected via an adhesive or friction, or a combination thereof.

The footwear component 100 may be customized so that the density of the footwear sole assembly 100, when joined with the footwear component 100, can be variable. The density may be variable in any direction of any region or sub-region of the customized sole assembly 400. For instance, the density of the customized footwear sole assembly 400 may vary from the upper surface 116 to the lower surface 118 of the footwear sole assembly 100. As another example, the customized sole assembly 400 may be constructed so that the density near the toe region 110 is greater than the density near the heel region 114. In yet another example, the density of the customized sole assembly 400 in the heel region 114 may vary from the lateral side to the medial side.

Variation in density of the customized sole assembly 400 in one embodiment may be achieved by varying a spatial form of the plurality of support members 240 of the footwear component 100. For instance, a first spatial form for a first support member 240 may be different from a second spatial form of a second support member 240. The first spatial form may be configured to increase density of the customized sole assembly 400 in a region associated with the first support member 240, and the second spatial form may be configured to reduce density of the customized sole assembly 400 in a region associated with the second support member 240.

For purposes of discussion, whether the density is increased or decreased by a spatial form of the support member 240 is determined relative to a neutral form of the support member 240, which is shown in FIGS. 6-7 and generally designated 230. The neutral form 230 is configured to substantially align with the form of the void 140 defined by the footwear sole assembly 100. It should be noted that the void depth may not be uniform in the footwear sole assembly 100—as discussed herein. As a result, the size and shape of the neutral form 230 may be determined relative to the void 140 associated with the neutral form 230, which is associated with a support member 240 that may be disposed in the void 140.

In the illustrated embodiments of FIGS. 6-7, the neutral form 230 is shown as a generally cylindrical form defined by an upper surface 232, lower surface 234 and a side surface 236. The side surface 236 in the illustrated embodiment may be defined by a plurality of line segments 238 extending from an upper perimeter edge 239 of the upper surface 232 to a lower perimeter edge 237 of the lower surface 234. For purposes of disclosure, three line segments 238 are shown, but many more may be defined about the entire perimeters of the upper surface 232 and the lower surface 234 to define the side surface 236. With a generally cylindrical form, the plurality of line segments 238 are parallel with respect to each other.

The neutral form 230, as discussed herein, may be substantially aligned to the form of an associated void 140. As a result, the cylindrical form provided for the neutral form 230 in the illustrated embodiment may vary substantially. For example, the neutral form may be an oblique cylinder or frustoconical. The upper surface 232 may be non-circular, such as being an elliptical shape or a polygon shape (e.g., a square or triangle), and likewise the upper surface 232 may be non-circular. In the case of a frustoconical structure for the neutral form 230, the plurality of line segments 238 defining the side surface 236 may not be parallel to each other, and instead may converge, if extended beyond the structure, to a single point. In another embodiment in which the upper surface 232 is smaller in area than the lower surface 234, the plurality of line segments 238 defining the side surface 236, or a subset thereof, may also converge toward a single point.

In the illustrated embodiment, line segments 238 that define the side surface 236 of the neutral form 230 are substantially straight. However, the present disclosure is not so limited—one or more or all of the line segments 238 are not straight, such as curved lines or defined by multiple line segments connected to each other at an angle other than 180°. Examples of curved lines similar to this arrangement but in conjunction with the support member 240 are depicted in the illustrated embodiment of FIG. 10.

The neutral form 230, as discussed herein in conjunction with one embodiment, may align substantially with the shape of an associated void 140 of the footwear sole assembly 100. A support member 240 that is substantially the same as the neutral form 230, and constructed of the same material as or materials with properties similar to the footwear sole assembly 100, may provide the custom footwear sole assembly 400 with a density similar to the footwear sole assembly 100 if absent the voids 140. If all of the voids 140 of the footwear sole assembly 100 receive a support member 240 that is substantially the same as the neutral form 230, the density of the customized footwear sole assembly 400 may be considered a baseline density profile from which customization changes can be determined based on consumer data.

In the illustrated embodiment of FIG. 6, changes to the support member 240 in the neutral form 230 are shown to impart varying degrees of density to the footwear sole assembly 100, thereby enabling production of the customized footwear sole assembly 400. Reduction in size of the form of the support member 240 relative to the neutral form 230 may result in formation of a space between the support member 240 and the void 140 in which the support member 240 is disposed. Such reductions may be localized to particular regions of the support member 240, and may decrease the density of the customized footwear sole assembly 400 in proximity to the support member 240. Additionally or alternatively, increasing the size of the form of the support member 240 at a region may result in interference between the support member 240 and the void 140, causing compression of the material in proximity to that region and increasing the density of the customized footwear sole assembly in proximity to the support member 240.

In the illustrated embodiment, the density of the customized footwear sole assembly 400 in proximity to the support member 240 may be a function of at least one of a) the amount of material increase or decrease relative to the neutral form 230 and b) the respective locations of the material increase or decrease relative to the neutral form 230.

In the illustrated embodiment, the support member 240A includes a form that is reduced in size near the middle of the support member 240A relative to the neutral form 230. This may result in less density with respect to the interface between the support member 240A and the void 140. The support member 240B is similarly reduced in size relative to the neutral form 230 but less so than the support member 240A, and therefore the support member 240 may yield additional density over the support member 240A.

The support member 240C in the illustrated embodiment includes a form that is enlarged in size near the middle relative to the neutral form 230. This increase in size may result in material compression near the middle of the support member 240C and adjacent material of the footwear sole assembly 100 that defines at least in part the void 140 in which the support member 240C is disposed. The material compression may enhance the density of the customized footwear sole assembly 400 in the region proximal to the support member 240C. This results in additional firmness in that region.

The support member 240D in the illustrated embodiment is enlarged more so than the support member 240C in the region near the middle relative to the neutral form 230. As a result, the density of the junction or interface between the support member 240D and the void 140 may be greater than the density achieved with the support element 240C.

By varying the size of the support member 240 relative to the neutral form 230 for a plurality of the support members 240, the density of the customized footwear sole assembly 400 at various regions thereof may be selectively controlled. As discussed herein, the density may be selectively varied based on consumer data, such as a pressure profile of the consumer's foot.

The support member 240 may be modified in a variety of ways relative to the neutral form 230 to yield a target density with respect to the support member 240 and the footwear sole assembly 100. In the illustrated embodiments of FIGS. 9-12, the support member 240 may include an upper support surface 242, a lower support surface 244, and a side surface 246 corresponding generally to the upper surface 232, the lower surface 234, and the side surface 246 of the neutral form 230, and may be defined in a similar manner to neutral form 230 but varied in size or configuration relative to the neutral form 230. The upper support surface 242, the lower support surface 244, and the side surface 246 may be modified relative to corresponding features of the neutral form 230 to yield a target density for the support member 240.

In the illustrated embodiment of FIG. 9, the support member 240 includes an upper support surface 242 and a lower support surface 244 that are substantially the same as the upper surface 232 and the lower surface 234 of the neutral form 230. However, the side surface 246 is different from the side surface of the neutral form 230. In the illustrated embodiment, the cross-sectional profile of the support member 240 depicts a displacement profile 248 with less material than the neutral form 230 and that peaks near the middle between the upper and lower support surfaces 242, 244.

The displacement profile 248 of the side surface 246 may be defined relative to the side surface 236 of the neutral form 230. The displacement profile 248 may identify an area of reduction or reduction area 247, which has a value that may functionally affect the density associated with the support member 240. In one embodiment, the reduction area 247 may be concave.

The greater the value of the reduction area 247 the less material included in the support member 240 in the reduction area 247. With less material, the density provided by the support member 240 in the reduction area 247 may be less relative to the neutral form 230 in the same area.

Additionally, or alternatively, as depicted in the illustrated embodiment of FIG. 12, the displacement profile 248 may identify an area of enlargement or enlargement area 249, which has a value that may also functionally affect the density associated with the support member 240. In one embodiment, the enlargement area 249 may be convex.

The greater the value of the enlargement area 249 the more material included in the support member 240 in the enlargement area 249. With more material, the density provided by the support member 240 in the enlargement area 249 may be greater relative to the neutral form 230 in the same area. Such a difference can be seen in comparing the support members 240 in the illustrated embodiments of FIGS. 11 and 12, with the displacement profile 248 in the illustrated embodiment of FIG. 12 providing a greater enlargement area 249 than that of the displacement profile 248 in the illustrated embodiment of FIG. 11, and therefore yielding a greater density or more firmness.

In the illustrated embodiment of FIG. 10, the upper support surface 242 and the lower support surface 244 deviate from the upper surface 232 and the lower surface 234, thereby affecting the displacement profile 248. One or both of the upper support surface 242 and the lower support surface 244 may deviate in this manner. The deviation in the illustrated embodiment results in an increase in the reduction area 247, but additionally or alternatively, the deviation may increase the enlargement area 249. It is noted that the upper support surface 242 or the lower support surface 244, or both, may protrude respectively beyond or inward, or a combination thereof, relative to the upper surface 232 and the lower surface 234.

In the illustrated embodiment of FIG. 13, the system for manufacturing the footwear component and producing custom footwear is shown and generally designated 600. For purposes of disclosure, the system 600 in the illustrated embodiment of FIG. 13 is depicted with several components, including a custom component generator, a manufacturing system, and an assembly system. It should be understood that the system 600 may include all or a subset of the components depicted in the illustrated embodiment. It should further be understood that the system 600 may include any combination of the one or more components described in the illustrated embodiment along with any of the one or more components described herein.

The system 600 may include a custom component generator 620 operably coupled to a physical data generator 610. The custom component generator 620 may be communicatively coupled to a support member database (not shown) with information pertaining to density and one or more support member configurations, such as those described in connection with the illustrated embodiments of FIGS. 1-12. An example configuration of the custom component generator 620 is also depicted in the illustrated embodiment to highlight that the custom component generator 620 may include one or more of the following: a processor 623, memory 621, an input interface 625, and an output interface 627. The input interface 625 may include one or more input communication interfaces, including, for example, wired communication and wireless communication capabilities. Likewise, the output interface 627 may include one or more output communication interfaces, including at least one wired interface and at least one wireless interface, or any combination thereof. The processor 623 and memory 621 may be configured to generate a model of the footwear component 200 according to one or more processes described herein.

For instance, the processor 623 and memory 621 may be programmed to receive physical characteristic information with respect to a consumer's foot view of the input interface 625. Additionally, or alternatively, the processor 623 and memory 621 may be programmed to receive user preference information via the input interface 625. The custom component generator 620 may communicate with the support member database to obtain support member information (e.g., density information) with respect to a neutral form 230 or one or more support members 240 based on the neutral form 230. Based on at least one of the physical characteristic information and the user preference information, and based on the support member information, the processor 623 of the custom component generator 620 may determine a configuration for each of a plurality of support members 240 to yield the footwear component 200.

The custom component generator 620 may obtain void information relating to the footwear sole assembly 100 including information relating to locations of the plurality of voids 140 of the footwear sole assembly 100. The footwear sole assembly 100 may vary from application to application, including different void locations or void configurations, or both, depending on the application. The custom component generator 620 may use the void information as a basis for determining a configuration for each of the plurality of support members 240 of the footwear component 200. The void information may be stored in a sole assembly database.

The support member database or the sole assembly database, or both, may be separate from the custom component generator 620. For instance, the support member database may be stored in a server component that is communicatively coupled to the custom component generator 620 via a network interface of the input and output interfaces 625, 627. The custom component generator 620 may query the support member database for support member information, or the sole assembly database for void information, or both.

The support member database or the sole assembly database, or both, may serve a plurality of custom component generators 620 respectively disposed at a plurality of point-of-sale locations. One or both of these databases may be updated from time to time such that changes to support member information or void information in the databases may be utilized by each of the plurality of custom component generators 620. The present disclosure is not limited to a support member database or a sole assembly database, or both, being available via a network interface—for instance, one or both of these databases may be integrated into the custom component generator 620 such that the support member information or the void information, or both, may be stored in the memory 621.

In one embodiment, the physical data generator 610 may form part of a point-of-sale system. Such a point-of-sale system may be a kiosk from which consumers can purchase footwear or obtain analysis for custom footwear, or both. The physical data generator 610 may obtain physical information relating to one or more physical aspects of the consumer. For instance, the consumer's weight and height are physical aspects that can be objectively measured with sensors. It should be understood, however, that the physical data generator 610 may not utilize a sensor to obtain one or more physical aspects, and that manual entry of one or more physical aspects is permissible in one embodiment based on a manual measurement.

As mentioned herein, one or more physical characteristics of the consumer's foot may be measured with one or more sensors, such as an active scanning system. The one or more sensors may include pressure plate on which the consumer may stand to obtain a foot pressure profile or measurements with respect to forces generated by the foot. An example of such a pressure profile is shown in the illustrated embodiment of FIG. 14 in the form of a contour map of pressure for a person standing on the pressure plate. The pressure profile is determined for both the left and right feet of the person, with the right foot having a heel region with increased pressure relative to the left foot and a greater maximum pressure in the heel region. The pressure profile may form physical information, which may be consumer data, provided to the custom component generator 620 for modification of one or more of the support members 240 relative to the neutral form 230. The illustrated embodiment of FIG. 14 depicts a static analysis of pressure for a person, but the present disclosure is not so limited—the analysis may be dynamic, such as while the person is walking or running. Such a dynamic analysis may form the basis for comparison against a neutral pressure profile, as discussed herein, which itself may be static or dynamic.

In one embodiment, the pressure profile of the person may be compared against a neutral pressure profile associated with the footwear sole assembly 100, if joined with a plurality of support members 240 in the neutral form 230. The neutral pressure profile may vary depending on the configuration, such as differently configured footwear sole assemblies 100 for different styles of footwear or footwear applications (e.g., hiking or running).

This comparison may yield areas of deviation between the neutral pressure profile and the pressure profile of the person. These deviation areas may form the basis for a modification to a support member 240 located in proximity to the deviation area. For instance, if a deviation area indicates an area of greater pressure relative to the neutral pressure profile, the support member 240 in that area may be modified as a function of the percentage increase in pressure for that area. In the case of a percentage increase in pressure relative to the neutral pressure profile, the reduction area 247 of the support member 240 may be increased as a function of the percentage to yield a support member 240 that decreases the density of the custom footwear sole assembly 400 in proximity to the support member 240, thereby potentially providing the person with a pressure profile in proximity to the support member 240 that is closer to or equal to the neutral pressure profile. In the case of a percentage decrease in pressure relative to the neutral pressure profile, the enlargement area 249 of the support member 240 may be increased as a function of the percentage to yield a support member 240 that increases the density of the custom footwear sole assembly 400 in proximity to the support member 240.

Modifying a plurality of the support members 240 based on the deviation areas may allow the custom component generator 620 to generate a footwear component 200 that, when joined with the footwear sole assembly 100, yields a custom footwear sole assembly 400 that accommodates the pressure profile of the person. The custom footwear sole assembly 400 generated in this manner may provide a pressure profile for one or more of the toe region 110, midfoot region 112, and heel region 114 that is closer to or equal to the neutral pressure profile. The percentage deviation of these one or more regions relative to the neutral pressure profile, when in use by the person whose pressure profile forms the basis for customization, may be less than 10%, possibly less than 5%.

The custom component generator 620 may generate custom component information, such as an encoded document, to facilitate production or manufacture of the custom footwear component 200. The encoded document may be in the form of a digital file or file stream that is readable for production purposes. The custom component generator 620 may provide the custom component information to variety of components in a variety of ways. In one embodiment, the custom component generator 620 may communicate the custom component information to an additive manufacturing system 660 that translates the custom component information for manufacture.

The manufacturing system 650 in the illustrated embodiment includes at least one of the following: an assembly system 670 and an additive manufacturing system 660. One or more of these components may be fully automated. The assembly system 670 or the additive manufacturing system 660, or both, may be configured similar to the custom component generator 620 such that the assembly system 670 or additive manufacturing system 650 includes a processor, memory, an input interface, and an output interface. In the illustrated embodiment, the additive manufacturing system 660 may receive the encoded information communicated via a network interface layer that utilizes the input and output interfaces. In order to manufacture the footwear component 200 for the consumer, the additive manufacturing system 660 to physically generate the footwear component 200 based on the encoded information. The additive manufacturing system 660 is not limited to obtaining the encoded information via a network connection—the encoded information may be obtained in any way.

The manufacturing system 650 may be located separate from devices that implement the physical data generator 610 or the custom component generator 620. For instance, the consumer may browse and ultimately purchase footwear via a digital storefront and provide consumer data via the storefront. All or some portions of the manufacturing system 650 may be located in proximity to the consumer at the time of purchase, such as in the case of a kiosk ordering system disposed at a store. For instance, the store may include a physical data generator 610, a custom component generator 620, and the additive manufacturing system 660 to generate the footwear component 200 and optionally one or more footwear components. The store may include an inventory of standard components, such as pre-manufactured footwear including the footwear sole assembly 100. In one embodiment, the consumer data can be obtained at the point of sale, the footwear component 200 can be manufactured (optionally at the point of sale), and the custom footwear sole assembly 400 in conjunction with footwear may be assembled at the point of sale.

For instance, the footwear sole assembly 100 is incorporated into footwear 500 in the illustrated embodiment of FIG. 15, and generally identified as 510. The footwear 500 includes an upper 502 joined with the footwear sole assembly 510 with an outsole 512 and a midsole 514. Not shown is the interior of the footwear 500, in which the footwear component 200 may be inserted or joined with the footwear sole assembly 510 to yield customized footwear. An insole may be inserted after the footwear component 200 to render the footwear 500 ready for use.

The additive manufacturing system 660, often referred to as a three-dimensional (3D) printer, may be configured in a variety of ways. The additive manufacturing system 660 generally utilizes any technique that deposits or creates material in successive layers to form a three-dimensional object. In one embodiment, the additive manufacturing system 660 may perform a 3D print operation that begins with computer readable instructions on the additive manufacturing system 660 (which may include a processor, memory, input and output interfaces similar to the custom component generator 620), when executed, cause a 3D printer to form the custom last according to an associated data object model based on the encoded information. Producing the custom component generally includes printing successive layers of a thermoplastic, polymeric, metal or other material, or a combination thereof, from an extrusion nozzle, where each layer of the material corresponds to a cross-sectional slice or other dimension of the footwear component 200. The 3D printer performing this task can include any 3D printer having a build volume suitably sized for a custom last. Example 3D printers include, without limitation, the Replicator 2 available from MakerBot Industries of Brooklyn, N.Y., the Cube available from 3D Systems of Rock Hill, S.C., and the Solidoodle 2 available from Solidoodle LLC of Brooklyn, N.Y. The selected 3D printing material can include any material providing the desired material properties. The material properties can include strength, melting temperature, and coefficient of thermal expansion. Example materials include, without limitation, thermoplastic materials, such as acrylonitrile butadiene styrene (ABS) and polylactide (PLA), metals, such as alloys, composites and combinations of the foregoing. Other thermoplastic materials and non-thermoplastic materials can be used in other embodiments where desired. Optional post production techniques include sanding, acetone washes, and/or decaling.

The assembly system 670 may be configured to track stock and the manufacturing process for the footwear component 200, so that after the footwear component 200 is complete, the footwear 500 can be assembled. Assembly may be done manually at the point of sale—but the present disclosure is limited to this assembly method so that assembly can be done in any way (manual or automated) at any location. In the illustrated embodiment, the footwear sole assembly 100, the footwear component 200, and any footwear components (such as a pre-manufactured footwear 500 without the footwear component 200) may be obtained and assembled to yield the custom footwear 500. It is noted that the illustrated embodiment of FIG. 13 outlines components of the system as well as the order in which they may be operated in accordance with a method of one embodiment to yield the custom footwear 500.

Directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. The use of directional terms should not be interpreted to limit the invention to any specific orientation(s).

The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual element(s) of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular. Any reference to claim elements as “at least one of X, Y and Z” is meant to include any one of X, Y or Z individually, and any combination of X, Y and Z, for example, X, Y, Z; X, Y; X, Z; and Y, Z. 

1. A method of generating a custom footwear component, said method comprising: providing a footwear sole assembly with a sole body having a plurality of voids, wherein each of the voids is constructed to accept a support member; obtaining consumer data pertaining to a physical characteristic of a consumer; generating an encoded description of a plurality of the support members based on the consumer data, wherein at least one of the support members is configured to provide at least one of space and interference with a portion of the sole body that defines a void; additively manufacturing the plurality of the support members in accordance with the encoded description; and disposing each of the plurality of the support members in one of the plurality of voids defined by the sole body.
 2. The method of claim 1 wherein said generating includes defining, in the encoded description, a shape of each of the plurality of the support members and one or more connecting members that connect two or more of the plurality of the support members, and comprising additively manufacturing the plurality of the support members and the one or more connecting members in accordance with the encoded description.
 3. The method of claim 2 comprising providing the sole body with one or more channels that respectively connect two or more of the plurality of voids, wherein the one or more channels are disposed on an upper surface of the sole body opposite a ground contacting surface of the sole body, and wherein the plurality of voids are open to the upper surface of the sole body.
 4. The method of claim 1 wherein each of said plurality of support elements is configurable based on the consumer data.
 5. The method of claim 4 wherein the support element includes an upper support surface, a lower support surface opposite the upper support surface, and a side surface extending from the lower support surface to the upper support surface.
 6. The method of claim 5 wherein the support element includes an inner surface defining a void within the support element.
 7. The method of claim 5 wherein a distance between the upper and lower support surfaces is variable based on a depth of a void associated with the support element.
 8. The method of claim 5 wherein the upper support surface and the lower support surface form bounded surfaces and define a boundary surface therebetween such that the upper support surface, the lower support surface, and the boundary surface define a closed surface object.
 9. The method of claim 8 wherein the boundary surface is defined by a plurality of parallel line segments extending from an upper perimeter edge of the upper support surface to a lower perimeter edge of the lower support surface.
 10. The method of claim 8 wherein at least a portion of the side surface of the support element is outside the boundary surface.
 11. The method of claim 10 wherein the at least the portion of the side surface is convex.
 12. The method of claim 8 wherein at least a portion of the side surface of the support element is internal to the closed surface object and spaced away from the boundary surface.
 13. The method of claim 10 wherein the at least the portion of the side surface is concave.
 14. A system for generating a footwear component for footwear, the footwear including a sole body with a plurality of voids, said system comprising: a sensor configured to sense a physical characteristic of a consumer to generate consumer data pertaining to the physical characteristic; and a control system operably coupled to the sensor, said control system configured to receive the consumer data, the control system configured to generate an encoded description of a plurality of support members based on the consumer data, wherein each of said plurality of support members is configured to be disposed within a void of the plurality of voids of the sole body, wherein at least one of said plurality of support members is configured to provide at least one of space and interference with a portion of the sole body that defines the void.
 15. The system of claim 14 comprising an additive manufacturing controller configured to direct a nozzle to dispense material in an additive manner in accordance with the encoded description to generate the footwear component including the plurality of support members.
 16. The system of claim 14 wherein the encoded description defines one or more connecting members configured to connect two or more of the plurality of support members.
 17. The system of claim 14 wherein each of plurality of support elements members is configurable based on the consumer data.
 18. A footwear component for footwear, the footwear including a sole body with a plurality of voids, the footwear component comprising: a support member including an upper support surface and a lower support surface opposite the upper support surface, said support member including an outer side surface extending from the lower support surface to the upper support surface, wherein said support member is configured to be disposed in a void of the plurality of voids defined by the sole body; and a plurality of connecting members, each of said plurality of connecting members being configured to connect a plurality of said support members, whereby said plurality of said support members are disposable into the plurality of voids of the sole body.
 19. The footwear component of claim 18 comprising a size and shape of each of said plurality of said support members being customizable based on consumer data pertaining to a physical characteristic of a consumer.
 20. A sole body for footwear comprising: a midsole having an upper midsole surface and a lower midsole surface, the upper midsole surface being positionable adjacent to an upper of the footwear, the midsole including a forefoot zone, a midfoot zone, a heel zone, and a plurality of voids defined at least in part by the upper midsole surface, wherein each of the plurality of voids is configured to accept a support member; the midsole including one or more channels defined at least in part by the upper midsole surface, said one or more channels disposed between at least two of said plurality of voids; and an outsole coupled to the lower midsole surface of the midsole, the outsole including a ground contacting surface. 